Automated key duplication system and method

ABSTRACT

An automated key duplication system that includes a system housing, a key identification system, a key cutting system, a key blank storage system, a key blank transfer assembly, and a duplicated key retrieval opening is disclosed. The key identification system may be housed at least partially within the system housing and is configured to identify a master key. The key blank storage system comprises a plurality of rods configured to removably couple to a plurality of key carriers. The key blank transfer assembly is housed within the housing is configured to remove one key carrier of the plurality of key carriers from the key blank storage system with the key retrieving apparatus and transport the one key carrier and the key blank coupled thereto from the key blank storage to the key cutting system. The duplicated key retrieval opening is positioned on the housing to receive the one key blank after the one key blank has been cut.

CROSS REFERENCE TO RELATED APPLICATIONS

This document claims the benefit of the filing date of U.S. ProvisionalPatent Application 61/671,058, entitled “Key Duplication Housing andStandard Reference Features” to Mueller et al., which was filed on Jul.12, 2012, the contents of which are hereby incorporated by reference.

This application is also a continuation-in-part application of theearlier U.S. Utility Patent Application to Hagen, et al. entitled“Master Key Identification and Feedback System,” application Ser. No.13/440,932 filed Apr. 5, 2012, now pending, which is acontinuation-in-part of the earlier U.S. Utility Patent Application toMueller et al. entitled “Multi-Key Duplication, Identification andCutting Machine with Clamp,” application Ser. No. 13/291,934 filed Nov.8, 2011, now pending, and is a continuation in part application of theearlier U.S. Utility patent application Ser. No. 13/292,023 to Muelleret al. entitled “Interaction between a Key Duplication Housing and a KeyBlank Carrier,” filed on Nov. 8, 2011, now pending, all of which arecontinuation-in-part applications of U.S. Utility Patent Application toMueller et al. entitled “Key Blank Carrier Adapted for Positioning a KeyBlank in a Cutter During Bit Cutting,” application Ser. No. 13/183,982filed Jul. 15, 2011, now pending, which claims the benefit of the filingdates of U.S. Provisional Patent Applications: 61/413,099 to Hagen etal. entitled “Key Duplication Machine Cutting System,” which was filedon Nov. 12, 2010, 61/497,468 to Hagen et al. entitled “Key Packaging andDuplication Systems,” which was filed on Jun. 15, 2011, 61/411,148 toMueller et al. entitled “Key Duplication Machine Identification System”which was filled on Nov. 8, 2010, and 61/364,644 to Hagen et al.entitled “Key Duplication Packaging and Standard Reference Features,”which was filed Jul. 15, 2010, the disclosures of each of which arehereby incorporated herein by reference.

This application is also a continuation-in-part application of theearlier U.S. Utility Patent Application to Mueller, et al. entitled “KeyBlank Carrier Adapted for Positioning a Key Blank in a Cutter During BitCutting,” application Ser. No. 13/728,890, filed Dec. 27, 2012, nowpending, which is also a continuation-in-part application of U.S.Utility Patent Application to Mueller et al. entitled “Key Blank CarrierAdapted for Positioning a Key Blank in a Cutter During Bit Cutting,”application Ser. No. 13/183,982 filed Jul. 15, 2011, now pending, thedisclosures of each of which are hereby incorporated herein byreference.

BACKGROUND

1. Technical Field

Aspects of this document relate generally to key duplication systems andmethods.

2. Background Art

Conventionally, when a master key for opening a lock is duplicated, itis duplicated by first classifying the master key to be able to identifyan appropriate key blank for the duplicate key, selecting theappropriate key blank to match the master key, placing the selected keyblank in a key cutter, and cutting the bit pattern of the master keyinto a blade of the key blank. Methods such as tracer bars and imagecapture are known for use in identifying a master key bit pattern.

Conventional systems have required the operation skills of a trainedworker to properly select the appropriate key blank. An example of anelaborate system used to assist a trained worker in selecting anappropriate key blank and appropriately positioning the appropriate keyblank and master key for cutting is disclosed in U.S. Pat. No. 5,443,339to Heredia et al., titled “Method and Apparatus for Aligning and CuttingSingle-sided and Double Sided Keys.” In Heredia, a plurality of clampingunits, each comprising its own clamp and cutter fixturing is provided.The trained worker selects an appropriate key blank and an appropriateclamping unit for the particular key blank and clamps the key blank intothe unit. Then the trained worker couples the clamping unit with acutting wheel for cutting. More recent master key identificationsystems, such as that disclosed in U.S. Pat. No. 6,836,553 to Campbellet al., titled “Key Identification System,” the disclosure of which ishereby incorporated herein by reference, automatically identifies theappropriate key blank and indicates that number for key selection.

A recent key duplication system described in International ApplicationNumber PCT/US2007/024522 to Freeman, et al. titled “Fully Automatic KeyDuplicating Machine with Automatic Key Model Identification System”sought to reduce the need for the operational skills of a trained workerby automatically identifying master keys and automatically cutting anddispensing a duplicate key from a limited selection of keys within thekey duplication system. Another recent key duplication system describedin U.S. Pat. No. 7,890,878 to Bass et al., titled “Object IdentificationSystem,” discloses a system that identifies an appropriate key blank byflashing a light adjacent the appropriate key blank on a product displaynext to a key blank cutter so that the user or a trained worker canselect the appropriate key for insertion into the key blank cutter.

SUMMARY

Various key duplication systems and methods of duplicating a key aredisclosed herein. According to one aspect, an automated key duplicationsystem comprises a system housing, a key identification system, a keycutting system, a key blank storage system, a key blank transferassembly, and a duplicated key retrieval opening. The key identificationsystem is housed at least partially within the system housing andconfigured to identify a master key. The key cutting system is housedwithin the system housing. The key blank storage system is housed withinthe housing and comprises a plurality of rods, a plurality of keycarriers removably coupled to the plurality of rods, and a plurality ofkey blanks, each one of the plurality of key blanks coupled to adifferent one of the plurality of key carriers. The key blank transferassembly is housed within the housing and comprises a key retrievingapparatus. The key blank transfer assembly is configured to remove onekey carrier of the plurality of key carriers from the key blank storagesystem with the key retrieving apparatus and transport the one keycarrier and the key blank coupled thereto from the key blank storage tothe key cutting system. The duplicated key retrieval opening ispositioned on the housing to receive the one key blank after the one keyblank has been cut.

Particular implementations and embodiments comprise one or more of thefollowing. One or more processors in communication with the keyidentification system, the key cutting system, the key blank storagesystem, and the key blank transfer assembly, wherein the one or moreprocessors are configured to receive master key information from the keyidentification system, access a database defining a plurality of knownkey models, compare physical characteristics of the master key withphysical characteristics of key models in the database to identify amodel of the master key, and determine one or more key blanks of theplurality of key blanks that are suitable for cutting to match themaster key. The key retrieving apparatus may be movable along a verticalaxis and a horizontal axis to align with the one key carrier, andmoveable from the key blank storage system to a key blank receivingaperture of the key cutting system. The plurality of key carriers may bepositioned by key blank type in at least two rows and at least twocolumns in the key blank storage system. Each of the plurality of keycarriers are removably mounted between slots on adjacent rods of theplurality of rods. The key blank transfer assembly may further comprisea horizontal belt system that moves the key retrieving apparatus alongthe horizontal axis and a vertical belt system that moves the keyretrieving apparatus along the vertical axis. The key blank storagesystem may comprise a double sided storage system comprising twoopposing series of rods of the plurality of rods, wherein the key blanktransfer assembly is positioned between two opposing series of rods ofthe plurality of rods, the key retrieving apparatus having access to keycarriers mounted among each of the two opposing series of rods. Aplurality of linear springs, each linear spring coupled to a differentrod of the plurality of rods and configured to bias the plurality of keycarriers towards the key blank transfer assembly. Each key carrier ofthe plurality of key carriers comprises one or more apertures and thekey retrieving apparatus comprises one or more tabs positioned to engagewith the one or more apertures when the key blank transfer assemblymoves the one key carrier from the key blank storage system to the keycutting system. A user interface in electronic communication with theone or more processors. The key retrieving apparatus may comprise aclamp and the plurality of rods comprises at least four rods, each ofthe four rods extending through an aperture on a different one or moreof the plurality of key carriers.

According to another aspect, an automated key duplication systemcomprises a system housing, a key identification system, a key cuttingsystem, a key blank storage system, a key blank transfer assembly, and aduplicated key retrieval opening. The key identification system ishoused at least partially within the system housing and configured toidentify a master key. The key cutting system is housed within thesystem housing. The key blank storage system is housed within thehousing and comprises a plurality of rods configured to couple to aplurality of key blanks. The key blank transfer assembly is housedwithin the housing and comprises a key retrieving apparatus, the keyretrieving apparatus movable along a vertical axis and a horizontal axisto align with one key blank of the plurality of key blanks andconfigured to remove the one key blank of from the key blank storagesystem and transport the one key blank coupled thereto from the keyblank storage to the key cutting system when the plurality of key blanksare individually coupled to the plurality of rods. The duplicated keyretrieval opening is positioned on the housing to receive the one keyblank after the one key blank has been cut.

Particular implementations and embodiments comprise one or more of thefollowing. The key blank transfer assembly further comprises ahorizontal belt system that moves the key retrieving apparatus along thehorizontal axis and a vertical belt system that moves the key retrievingapparatus along the vertical axis. The key blank storage systemcomprises a double sided storage system comprising two opposing seriesof rods of the plurality of rods, wherein the key blank transferassembly is positioned between two opposing series of rods of theplurality of rods, the key retrieving apparatus having access to keycarriers mounted among each of the two opposing series of rods. Aplurality of linear springs, each linear spring coupled to a differentrod of the plurality of rods and configured to bias the plurality of keyblanks towards the key blank transfer assembly when the plurality of keyblanks are coupled to the plurality of rods.

According to another aspect, a method of key duplication comprisesidentifying a master key with a key identification system within ahousing, moving a key blank transfer assembly along a vertical axis anda horizontal axis to align a key retrieving apparatus of the key blanktransfer assembly with one key blank of a plurality of key blanksremovably coupled to a plurality of rods of a key blank storage system,the key blank transfer assembly housed within the housing, removablycoupling the key retrieving apparatus to a key blank carrier coupled tothe one key blank, transferring the one key blank from the key blankstorage system to a key cutting system housed within the housing,cutting the one key blank to match the master key, and dispensing thecut one key blank.

Particular implementations and embodiments may comprise one or more ofthe following. determining, with a processor housed within the housing,X-Y coordinates for the one key blank, the processor being in electroniccommunication with the key identification system, the key blank transferassembly, and the key cutting system. Inserting the one key blank into alead-in funnel surrounding a key blank receiver opening on the keycutting system. Removably coupling the key retrieving apparatus to thekey blank carrier may comprise clamping the key blank carrier coupled tothe one key blank with the key retrieving apparatus, the key retrievingapparatus comprising a key retrieving apparatus, and removing the keyblank carrier from a mounted position between two rods of the pluralityof rods. Removably coupling the key retrieving apparatus to the keyblank carrier coupled to the one key blank may comprise biasing the onekey blank toward the key blank transfer assembly with a linear springcoupled to one rod of the plurality of rods.

Aspects and applications of the disclosure presented here are describedbelow in the drawings and detailed description. Unless specificallynoted, it is intended that the words and phrases in the specificationand the claims be given their plain, ordinary, and accustomed meaning tothose of ordinary skill in the applicable arts. The inventors are fullyaware that they can be their own lexicographers if desired. Theinventors expressly elect, as their own lexicographers, to use only theplain and ordinary meaning of terms in the specification and claimsunless they clearly state otherwise and then further, expressly setforth the “special” definition of that term and explain how it differsfrom the plain and ordinary meaning Absent such clear statements ofintent to apply a “special” definition, it is the inventors' intent anddesire that the simple, plain and ordinary meaning to the terms beapplied to the interpretation of the specification and claims.

The inventors are also aware of the normal precepts of English grammar.Thus, if a noun, term, or phrase is intended to be furthercharacterized, specified or narrowed in some way, then such noun, term,or phrase will expressly include additional adjectives, descriptiveterms, or other modifiers in accordance with the normal precepts ofEnglish grammar. Absent the use of such adjectives, descriptive terms,or modifiers, it is the intent that such nouns, terms, or phrases begiven their plain, and ordinary English meaning to those skilled in theapplicable arts as set forth above.

Further, the inventors are fully informed of the standards andapplication of the special provisions of 35 U.S.C. §112, ¶6. Thus, theuse of the words “function,” “means” or “step” in the DetailedDescription or Description of the Drawings or claims is not intended tosomehow indicate a desire to invoke the special provisions of 35 U.S.C.§112, ¶6, to define the invention. To the contrary, if the provisions of35 U.S.C. §112, ¶6 are sought to be invoked to define the inventions,the claims will specifically and expressly state the exact phrases“means for” or “step for”, and will also recite the word “function”(i.e., will state “means for performing the function of [insertfunction]”), without also reciting in such phrases any structure,material or act in support of the function. Thus, even when the claimsrecite a “means for performing the function of . . . ” or “step forperforming the function of . . . ,” if the claims also recite anystructure, material or acts in support of that means or step, or thatperform the recited function, then it is the clear intention of theinventors not to invoke the provisions of 35 U.S.C. §112, ¶6. Moreover,even if the provisions of 35 U.S.C. §112, ¶6 are invoked to define theclaimed aspects, it is intended that these aspects not be limited onlyto the specific structure, material or acts that are described in theembodiments, but in addition, include any and all structures, materialsor acts that perform the claimed function as described in alternativeembodiments or forms of the disclosure, or that are well known presentor later-developed, equivalent structures, material or acts forperforming the claimed function.

The foregoing and other aspects, features, and advantages will beapparent to those artisans of ordinary skill in the art from theDESCRIPTION and DRAWINGS, and from the CLAIMS.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will hereinafter be described in conjunction with theappended drawings, where like designations denote like elements, and:

FIG. 1 is a perspective view of the outside of a key duplication system;

FIG. 2 is a perspective view of a key blank storage system and a keyblank transfer assembly;

FIG. 3 is a front view of a portion of a key blank storage system;

FIG. 4 is a side view of an automated key duplication system;

FIG. 5 is a front view of a second embodiment of an automated keyduplication system;

FIG. 6 is a side view of a second embodiment of an automated keyduplication system;

FIG. 7 is a perspective view of a key retrieving apparatus;

FIG. 8 is a perspective view of aspects of a third embodiment of anautomated key duplication system;

FIG. 9 is a perspective view of a key retrieving apparatus in aretracted position;

FIG. 10 is a perspective view of a key retrieving apparatus in anextended position; and

FIG. 11 is a perspective view of a second embodiment of a key blankstorage system and a key blank transfer assembly.

DESCRIPTION

This disclosure, its aspects and implementations, are not limited to thespecific components or assembly procedures disclosed herein. Manyadditional components and assembly procedures known in the artconsistent with the intended automated key duplication systems and/orassembly procedures for automated key duplication systems will becomeapparent for use with implementations of automated key duplicationsystems from this disclosure. Accordingly, for example, althoughparticular systems are disclosed, such systems and implementingcomponents may comprise any shape, size, style, type, model, version,measurement, concentration, material, quantity, and/or the like as isknown in the art for such automated key duplication system andimplementing components, consistent with the intended operation of anautomate key duplication system.

Various embodiments of the automated key duplication systems and methodsdescribed herein are configured to allow consumers or other users toduplicate a master key without any prior training or without theassistance of a store employee. As shall be shown in greater detail inembodiments described herein, some automated key duplication systemscontemplated in this disclosure are configured such that a consumer isrequired only to insert the master key into a key identification systemand retrieve a duplicated key from the automated key duplication systemhousing. This configuration is not only easier for the consumer, butreduces the likelihood of human error occurring during key duplication,resulting in a more efficient method and system than those previouslyknown in the art.

FIG. 1 illustrates an embodiment of an automated key duplication systemcomprising a system housing 2, a key identification system 4 housed atleast partially within the system housing 2, a key cutting system 6housed within the system housing 2, a key blank storage system 8 housedwithin the system housing 2, a key blank bulk transfer assembly 10housed within the system housing 2, and a duplicated key retrievalopening 26 positioned on the system housing 2. Any of a number of keyidentification systems and key cutting systems may be utilized in anautomated key duplication system. Many are referenced herein and othershave been incorporated by reference. A system housing 2 may comprise anyshape, size, configuration, and the like that allows for at leastpartial housing of the key identification system 2, the key cuttingsystem 6, the key blank storage system 8, the key bank transfer assembly10, the processor 11, and any necessary payment devices. FIG. 1illustrates a non-descript housing shape to illustrate that the shape ofthe housing is not critical to the operation of the components within.By bulk storing key blanks in carriers and then retrieving the keyblanks from a known location and transferring the key blanks, whenneeded, to a different location for cutting, any number of key varietiesmay be stored and used as requested by customers.

FIG. 2 illustrates a perspective view of an embodiment of a key blankstorage system 8 and a key blank transfer assembly 10. In one or moreembodiments, a key blank storage system 8 comprises a plurality of rods12. The plurality of rods 12 may be arranged horizontally, as in FIG. 2,vertically, or diagonally. As shown in greater detail in FIG. 3, each ofthe plurality of rods 12 comprises a plurality of slots 24. The slots 24may comprise grooves partially or wholly circumnavigate the rod 24, andtypically comprise a width sufficient to hold a portion of either a keycarrier 14 or a key blank 15 (without a carrier) within the slot 24. Theslots 24 may be tapered to allow for easier and more precise insertionof the key blanks 15 and/or key carriers 14 when being loaded into thekey blank storage system. In specific embodiment shown in FIGS. 2 and 3,two adjacent rods 12 are spaced at a distance from each other thatallows either a key carrier 14 or a key blank 15 to be held between thetwo adjacent rods 12. In particular embodiments, the rods 12 arearranged 2-deep, such that the key carrier 14 is positioned between fourtotal rods 12: two rods 12 on top and two rods 12 on bottom. As bestillustrated in FIG. 3, opposing edges of a key carrier 14 are alignedwith and held between slots 24 on two adjacent rods 12 for storage untilthe key blank transfer assembly 10 removes the key carrier 14 frombetween the adjacent rods 12. Although not shown, it is alsocontemplated that opposing edges of a key blank 15 may similarly fitbetween slots 24 of two adjacent rods 12. Positioning of the rods 12 andthe slots 24 on the rods 12 creates a grid-like system of key blanks 15comprising a plurality of rows and columns. For example a plurality ofkey carriers 14 between two or more rods 12 forms a row of key blanks15, and alignment of the slots 24 of three or more rods 12 forms atleast two columns of key carriers 14. It will also be clear to those ofordinary skill in the art that the described system is not limited touse with key blanks or key carriers. Other products may similarly beloaded into carriers and distributed through this system by skipping thekey engraving steps of the method.

Although FIG. 2 illustrates one embodiment of a grid-like system, othergrid-like systems within the key blank storage system 8 are alsocontemplated. For example, key blanks 15 and/or key carriers 14 may hangor be mounted from a plurality of rods, the arrangement of the rodsforming a plurality of columns and rows of key blanks 15 and/or keycarriers 14. Alternatively, linear springs may bias the key blanks 15and/or key carriers mounted on a rod toward the key blank transferassembly 10 for transfer to the key cutting system 6.

Any of a number of key carriers 14 and key blanks 15 may be utilized inany of the automated key duplication systems disclosed herein. Forexample, any of the key carriers 14 and key blanks 15 described in U.S.patent application Ser. No. 13/292,023, which was previouslyincorporated by reference, are contemplated. The key carrier 14 mayfurther comprise one or more apertures 30 (shown in FIG. 7) sized andpositioned to allow tabs 130 from a key retrieving apparatus 28, 78, 128to hold the key carrier 14 during transfer and/or during cutting. In theembodiments shown in FIG. 7, the aperture 30 comprises a circularboundary and a guide wall extending from the key carrier 14.

FIG. 2 also illustrates a non-limiting example of a key blank transferassembly 10. Various embodiments of key blank transfer assembliescontemplated herein are a configured for translational movement acrossboth a horizontal (X) axis 18 and a vertical (Y) axis 16. Thisconfiguration allows for retrieval of a key blank 15 and/or key carrier14 positioned on a grid-system, such as that formed by the slots 24 androds 12 of the key blank storage system. For example, each key blank 15and/or key carrier positioned between two rods may be assigned aspecific grid location coordinate. When a master key is identified by akey identification system 4, the processor 11 determines a suitable keyblank 14 in the key blank storage system 8. In one or more specificembodiments, the key blank transfer assembly 10 comprises a keyretrieving apparatus 28, or alternatively a key retrieving apparatus 128positioned on one end of the mechanical arm, that is configured toretrieve a key blank 15 from the key blank storage system 8. The keyretrieving apparatus 28, 128 may move to a specific grid locationcoordinate in the key blank storage system 8 responsive to a commandfrom the processor 11 after a master key has been identified.

In operation, when a key blank type is determined after keyidentification and/or selected by a user, the key retrieving apparatus28 moves along the horizontal axis 18 and vertical axis 16 until the keyretrieving apparatus 28 is facing the desired key blank 15 from storage.Once positioned facing the key blank 15, the key retrieving apparatus 28reaches towards the key blank 15 and grips or otherwise couples to thekey blank 15 or the key carrier 14 (see also FIG. 7). Once the selectedkey blank 14 is gripped or coupled to key retrieving apparatus 28, thekey blank transfer assembly 10 moves the key blank 15 from itspositioning on the key blank storage system 8 to the key blank receivingopening 132 of the key cutting system 6 at a key cutting station. In oneor more embodiments, a lead-in funnel 134, or tapered entry port,surrounds the key blank receiver opening 132 for easier entry of the keyblank 15 into the key blank receiver opening 132, although in many casesno lead-in funnel or tapered entry port is needed. The key retrievingapparatus transitionally inserts the key blank 15 and/or key carrier 14into the key cutting system 6 which cuts the key according to its normalprocesses. After the key blank 15 is cut, it is removed from the keycutting system 6 by the key retrieving apparatus 28. In one or moreembodiments, once the key retrieving apparatus 28 has removed the keyblank 15 and/or key carrier 14 from the key blank storage system 8, thekey retrieving apparatus 28 moves to a customer return station to dropthe key for the customer retrieve, and then may return to its originalposition or continue to the next operation it needs to execute.

Various configurations of a key blank transfer assembly 10 that allowfor horizontal and vertical translational movement are contemplatedherein. In the specific embodiment shown in FIG. 2, the key blanktransfer assembly 10 comprises a horizontal belt system 20 and avertical belt system 22. Embodiments utilizing the horizontal 20 andvertical 22 belt systems typically also comprise one or more firstsupport bars 17, such as the two horizontal support bars 17 shown inFIG. 2. The support bar 17 may be positioned substantially horizontal onopposing ends of the key blank transfer system. The support bars 17 arecoupled to the belts and gears of the horizontal 20 and vertical 22 beltsystems such that the gears slide along the support bars 17. A thirdbelt system 13 (shown in FIG. 4) may also be included to rotate thesupport bar 17.

Also included in one or more embodiments of the key blank transferassembly is one or more second support bars, typically a verticalsupport bar 19. The vertical support bar 19 is operably coupled to thebelts and gears of the horizontal belt system 20 such that as thevertical support bar 19 rotates, the belt or belts in the horizontalbelt system move the belts and gears of the vertical belt system 22 in ahorizontal direction allowing for horizontal movement of the keyretrieving apparatus 28. The key retrieving apparatus 28 may be coupledto the belts of the vertical belt system 22 such that as the supportbars 17 rotate, the belts of the vertical belt system rotate around thegears, thus moving the key retrieving apparatus 28 in the verticaldirection. In one or more embodiments, the key retrieving apparatus 28is slidably mounted to one or more vertical guide bars 21. As the keyretrieving apparatus 28 moves in a substantially vertical direction, thekey retrieving apparatus 28 slides vertically along the vertical guidebars 21. Thus in operation, the vertical belt system 22 and thehorizontal belt system 22 are configured to move the key retrievingapparatus along the horizontal (X) axis 18 and along the vertical (Y)axis 16 to retrieve a key blank 15 and/or key carrier 14 on a grid likesystem as described above.

The key retrieving apparatus 28 may comprise any apparatus any apparatusadapted to retrieve the key carrier 14 and key blank 15 from the keyblank storage system 8, move the key carrier 14 and key blank 15 to thekey cutting system 6 for cutting, move the key from the key cuttingsystem 6 near a duplicated key retrieval opening 26, release the keycarrier 14 and key blank 15 to the duplicated key retrieval opening 26for customer retrieval. A particular embodiment of a key retrievingapparatus is depicted in FIGS. 2, 9, and 10. In a particular embodiment,the key retrieving apparatus 28 comprises a body 94 with a chamber 96extending at least partially therethrough. The body 94 is typicallycylindrical, although varying embodiments may comprise alternate shapesand configurations.

Particular embodiments of the key retrieving apparatus 28 furthercomprise a retrieval loop 93 coupled to one or more arms 92. In theembodiment depicted in FIGS. 9 and 10, the key retrieving apparatuscomprises two arms 92 coupled to the retrieval loop 93. The arms 92 areoperably coupled to one or more gears 91 positioned on or adjacent tothe body 94. In operation, the key retrieving apparatus 28 is operableto move the retrieval loop 93 between a retracted position (depicted inFIG. 9) and an extended position (depicted in FIG. 10). In a retractedposition, the retrieval loop 93 is positioned at least partially withinthe chamber 96 of the body 94, while terminating ends 97 of the arms 92opposite the retrieval loop 93 are positioned within or proximate toslots 95 on the body 94. As such, the arms 92 extend from the chamber 96through the body 94 to the slots 95.

Responsive to the one or more gears 91, the arms 92 move the retrievalloop 93 from the retracted position within the chamber 96 to theextended position outside the chamber (shown in FIG. 10). As the one ormore gears 91 rotate, the terminating ends 97 of the arms move from oneside of the body 94 to an opposite side of the body 94. In so doing, theretrieval loop 93 moves from within the chamber 96 to outside thechamber 94. In this extended position, the key retrieving apparatus 28is positioned to removably couple a key carrier 14. For example, in theparticular embodiment depicted in FIG. 10, the retrieval loop 93 coupledto a raised lip 98 on the key carrier 14. The raised lip 98 may extendthrough a hole on in the retrieval loop 93 when the key carrier 14 iscoupled to the retrieval loop 93. Once coupled, the retrieval loop 93returns to the retracted position within the chamber 96 in particularembodiments. Thus, the chamber 96 is sized to hold the key blank 15 andkey carrier 14 therein in certain embodiments.

In operation of a specific embodiment, the key blank transfer assembly10 moves the key retrieving apparatus 28 to a position on the horizontal(X) axis 18 and vertical (Y) axis 16 to retrieve a particular key blank15 coupled to a key carrier 14 positioned between a plurality of rods12. The retrieval loop 93 then moves from a retracted position withinthe chamber 96 to an extended position outside the chamber and adjacentto the particular key carrier 14. Once adjacent to the particular keycarrier 14, the key retrieving apparatus 28 may move the retrieval loop93 such that a lip 98 of the key carrier 14 is removably coupled to theretrieval loop 93 within a hole extending through the retrieval loop.The retrieval loop 93 may then to the retracted position within thechamber 96 such that the key blank 15 and key carrier are at leastpartially housed within the chamber 96. The key retrieving apparatus 28then moves the key blank 15 and key carrier to the key cutting system 6for cutting where the key blank 15 is cut. Particular embodiments of thekey retrieval apparatus 28 are also configured to insert a key carrier14 back into a position between a plurality of rods 12. Thisconfiguration is advantageous when a wrong or undesired key blank 14 isretrieved.

Embodiments of an automated key duplication system 1 may comprise eithera single-sided key blank storage system 8, an example of which is shownin FIG. 2, or a double-sided key blank storage system, an example ofwhich is shown in FIG. 4. In embodiments comprising a double-sided keyblank storage system 8, the key blank transfer assembly 10 is typicallypositioned between the two or more key blank storage systems 8. Variouskey blanks 15 are stored on the racks formed by the plurality of rods 12and slots such that the head of the key blank 15 is positioned proximatethe key blank transfer assembly 10. The key retrieving apparatus 28previously described is configured to retrieve key blanks 15 and/or keycarriers 14 from either side of a double-sided key blank storage system8 and move they key blank 15 and/or key carriers as previouslydescribed.

Referring now to FIG. 11, in other embodiments, an automated keyduplication system comprises a key blank storage system 68. In aparticular embodiment of a key blank storage system 68, a plurality ofkey blanks 15 and/or key carriers 14 are arranged in a grid like systemcomprising a horizontal (X) axis and a vertical (Y) axis. The key blankstorage system 68 typically comprises a plurality of rods 72 upon whichone or more key blanks 14 are mounted or otherwise removably coupled. Inthe specific embodiment depicted in FIG. 11, a plurality of key blanks14 may be removably coupled on a single rod 72. The rod 72 may extendthrough an aperture in the key carrier 14 to removably couple the keycarrier 14 to the rod 72. The plurality of a key blanks 14 on each rod72 may each be coupled to a particular type of key blank 15, thusassociated a particular coordinate in the key blank storage system 68with a particular type of key blank 15. More particularly, alignment ofthe key carriers 15 may be arranged in rows and columns in one or moreembodiments. In certain embodiments, a biasing element, such as aspring, is coupled to each rod 72 to push the key blank 15 and/or keycarrier 14 toward a terminating end of the rod 72.

The automated key duplication system depicted in FIG. 11 furthercomprises a key blank transfer assembly 70 comprising a key retrievingapparatus 78. The key blank transfer assembly 70 is configured to movealong both a horizontal (X) axis and a vertical (Y) axis to retrieveparticular key blanks 15 positioned at specific locations on the keyblank storage system 68. The key blank transfer assembly 70 is typicallyoperably coupled to the processor and moves responsive to commands fromthe processor. The key blank transfer assembly 70 may comprise one ormore belts, one more hydraulic elements, gears, threaded screws, one ormore biasing elements, any other moving elements known in the art, orany combination thereof configured to move the key blank transferassembly to retrieve a key blank 15, move the key blank 15 to the keycutting system 6, and/or move the cut key blank 15 to a key retrievalopening 26. In a particular embodiment, the key blank transfer assembly70 comprises vertical guide bars 71 and horizontal guide bars 73. Thevertical guide bars 71 are configured to allow the key retrievingapparatus 78 to move vertically, while the horizontal guide bars 73 areconfigured to allow the key retrieving apparatus 78 to movehorizontally. In a particular embodiment, a rotation of a threadedhorizontal screw 74 moves the key retrieving apparatus 78 horizontally,and rotation of a threaded vertical screw 69 moves the key retrievingapparatus 78 vertically. A similar configuration may be utilized in anyof the key duplicating systems described throughout this application.Similarly, any of the key blank transfer assemblies described herein maybe substituted in the embodiment depicted in FIG. 11 without departingfrom the scope of this disclosure.

Embodiments of the key retrieving apparatus 78 may comprise anyconfiguration that allows the key retrieving apparatus 78 to grasp a keyblank 15 and/or key carrier 14, remove the key blank 15 and/or keycarrier 14 from key blank storage system 68, hold the key blank 15and/or key carrier 14 as the key retrieving apparatus 78 moves the keycarrier 14 from the key blank storage system 68 to the key cuttingsystem 6, and hold the key blank 15 and/or key carrier as the keyretrieving apparatus 78 moves the key carrier 14 from the key cuttingsystem 6 to the key retrieval opening 26. In the particular embodimentdepicted FIG. 11, the key retrieving apparatus 78 comprises a clamp 79,a mounting pin 77, and an extractor 75. The mounting pin 77 is typicallysized to support or align the key carrier 14 as clamp 79 holds the keycarrier 14 by extending through a hole or notch in the key carrier 14.The mounting rod 77 may also apply force to the key carrier 14 when thekey carrier is loaded key cutting system 6. The extractor 75 is shapedand configured to remove pieces of the key carrier 14 left in the keycutting system 6 during cutting (when necessary).

The clamp 79 may comprise two or more opposing arms each having a notch,groove, or corner shaped to support or hold opposing edges of the keycarrier 14 as the clamp 79 closes on the key carrier 14. Opening andclosing of the clamp 79 may be accomplished through any mechanismpreviously known in the art. In particular embodiments, the clamp 79 isconfigured to release the key carrier 14 as the key blank 14 is beingcut in the key cutting system 6, then grip the key carrier again afterthe key blank 14 has been cut by the key cutting system.

FIGS. 5 and 6 illustrate another exemplary embodiment of an automatedkey duplication system 101. Many of the aspects of the automated keyduplication system are similar to those described in relation to theautomated key duplication systems previously described. Moreover,various aspects of the automated key duplication systems disclosedherein may be combined with aspects of the other without departing fromthe scope of this disclosure. Like the automated key duplication systempreviously described, the automated key duplication system shown inFIGS. 5 and 6 comprises a system housing 2, a key identification system4, a key cutting system 6, key carriers, 14, and key blanks 15. Theautomated key duplication system also comprises a key blank storagesystem 108 and a key blank transfer assembly, with modifications fromthe embodiments previously described.

As shown in FIGS. 5 and 6, one or more embodiments of an automated keyduplication system include a key blank storage system 108 comprising aplurality of rods 112. A plurality of key blanks 15 and/or key carriers14 are typically removably coupled or mounted to each one of theplurality of rods 112. For example, in the exemplary embodiment shown inFIG. 5, a key blank storage system 108 comprises sixteen rods, eachconfigured to hold fifty key carriers 14. In this embodiment, then, thekey blank storage system 108 is configured to hold approximately 800 keyblanks 15. Other embodiments comprising fewer and greater numbers ofrods 112 each capable of holding fewer and greater key blanks 15 arealso contemplated.

FIGS. 5 and 6 also illustrate one exemplary arrangement of the pluralityof rods 112 in the key blank storage system 108. Like other key blankstorage systems 8 previously described herein, the plurality of rods 112of the key blank storage system 108 may, in particular embodiments, bearranged in a grid-like system comprising one or more columns of keyblanks 15 and one or more rows key blanks 15. The embodiment shown inFIG. 5 comprises two columns each comprising eight rods 112, and thuseight rows of key blanks 15. For more efficient use of space within thehousing 2, the rods 112 of the two columns may be offset from oneanother such that the key blades of key blanks 15 removably coupled to arod 112 in a first column of rods 112 fits between two rods 112 of asecond column of rods 112, as shown in FIG. 5.

In one or more embodiments, the key blank storage system 108 furthercomprises a plurality of linear springs 124. Typically, the key blanksstorage system 108 comprises one linear spring 124 associated with onerod 112 of the plurality of rods 112. For example, an embodimentcomprising sixteen rods 112 comprises sixteen linear springs 124, eachone of sixteen linear springs 124 associated with a different rod 112 ofthe sixteen rods 112. In other embodiments, the number of linear springs124 may be greater than or less than the number of rods 112. Each one ofthe plurality of linear springs 124 is configured and positioned toadvance or bias key blanks 15 and/or key carriers 14 to a productpick-up point on each rod 112. Each linear spring 124 may be coiledabout at least a portion of a rod 112, or may alternatively bepositioned adjacent to a rod 112. In other embodiments, other springs orbiasing elements may be utilized to bias the key blanks 14 and/or keycarriers to a product pick-up point on each rod 112. The key blankstorage system 108 further comprises a stop element positioned on therods 112 to prevent the linear springs 124 from biasing the key blanks15 and/or key carriers 14 off the rods 112 the key retrieving apparatus128 is positioned to receive one at the product pick-up point.

One or more embodiments of an automated key duplication system furthercomprise a key blank transfer assembly 110 configured to retrieve onekey blank 15 and/or key carrier 14 from the key blank storage system 108and transfer or move the key blank 15 and/or key carrier 14 to the keycutting system 4 for cutting of the key blank 15 to duplicate a masterkey. Once the key blank 15 has been cut by the key cutting system 6 toduplicate the master key, the key blank transfer assembly 110 deliversthe cut key blank 15 to a duplicated key retrieval opening 26 positionedto allow retrieval of the cut key blank 15 by a user.

One or more embodiments of the key blank transfer assembly comprise atleast one horizontal support bar 117 and at least one vertical supportbar 119. Although the support bars 117, 119 are described as verticaland horizontal, it is contemplated that the support bars 117, 119comprise multi-direction support bars 117, 119, and are thus not limitedto vertical and horizontal positioning. Positioning of the horizontalsupport bar 117 and vertical support bar 119 allows key retrievingapparatus 128 (shown in FIG. 7) to move to a desired X, Y coordinate forretrieval of an appropriate key blank 14 coupled to one of the pluralityof rods 112. The appropriate key blank 14 may be comprise a key blank 14selected by a user or identified as by the key identification system 4.Movement along the support bars 117, 119 may be facilitated by rotationof either support bars 117, 119 that in combination with one or moregears effectuates movement of the key retrieving apparatus 128.Alternatively, a motor may move the key retrieving apparatus 128 alongthe support bars 117, 119. In still other embodiments, movement of thekey retrieving apparatus 128 may be effectuated through any number ofmechanisms or configurations apparent to a person having ordinary skillin the art.

FIG. 7 illustrates an exemplary embodiment of a key retrieving apparatus128 that may be utilized in conjunction with any of the key blanktransfer assemblies 10, 110 described herein. Those of ordinary skill inthe art will also understand and may devise other key retrievingapparatus which will serve the purposes described herein. Moreover, thekey retrieving apparatus 128 shown in FIG. 7 may either move inconjunction with the key transfer assembly 10, 110, or, alternativelyremain positioned near the key blank receiver opening 132 even as thekey blank transfer assembly 10, 110 retrieves a key blank 15. Forexample, in one or more embodiments, the key retrieving apparatus 28clamps a key carrier 15 held in the key blank storage system 8 and movesthe key to the key retrieving apparatus 128 positioned proximate the keyblank receiver opening 132. Once the key carrier 14 is coupled to thekey retrieving apparatus 128, as shown in FIG. 7, the key retrievingapparatus 128 may move toward the key blank receiver opening 132 toinsert the blade of the key blank 15 into the key blank receiver opening132 for key cutting. Once the key is cut, the key retrieving apparatus128 removes the cut key blank 15 from the key blank receiver opening andejects the key blank 15 and key carrier 14 from the key retrievingapparatus 128.

In other embodiments, the key retrieving apparatus 128 moves with thekey blank transfer assembly 10, 110 to the appropriate position on thegrid-like configuration of the key blank storage system 8, 108. As shownin FIG. 7, the key retrieving apparatus comprise one or more tabs 130that align with one or more apertures 30 on the key carrier 14 forcoupling and transfer of the key blank 15 and key carrier 14 to the keycutting system 6.

FIG. 8 illustrates another embodiment of automated key duplicationsystem that comprises a key blank storage system comprising a carousel80 housing a plurality of key carriers 14. The carousel may comprise aplurality of feeding sleeves 81 positioned around the carousel 80. Eachof the plurality of feeding sleeves 81 is typically configured to houseportions of a plurality of key blanks 14 and/or carriers 15. In oneparticular embodiment, the blade of the key blank 15 and thecorresponding portion of the key carrier 14 extend from the feedingsleeve, while the head of the key blank 15 is housed within the feedingsleeve 81. A spring or biasing element may be associated with eachfeeding sleeve to bias the key blanks 15 and/or key carriers towards anejecting end of each feeding sleeve 81. Particular embodiments of thekey carriers may comprise one or more ridges 85 configured to engagewith the belt 83. Alternatively, the key head may be configured with theone or more ridges configured to engage with the belt 83.

In an embodiment comprising a carousel 80 key blank storage system, aswell as other key blank storage systems described herein, the key blanktransfer assembly of one or more embodiments of the automated keyduplication system may comprise a belt drive feeder 82. The belt drivefeeder is positioned to receive a key blank 15 from one of the pluralityof feeding sleeves 81, move the key blank 15 into the key blank receiveropening 132 of the key cutting system 6 for cutting, and eject the cutkey 15 into the duplicated key retrieval opening 26.

In operation, the carousel 81 of the key blank transfer assembly may,upon receiving a command from the user and/or processor 11, rotate toalign the proper key blank 15 with the belt drive feeder 82. Oncealigned, the appropriate key blank 15 and key carrier 14 are pushed orotherwise moved into the belt drive feeder 82, and one or more belts 83within the belt drive feeder 82 shuttle the key blank 15 into the keyblank receiver opening 132 for cutting in the key cutting system 6.After cutting, the belt 83 of the belt drive feeder remove the key blank15 from the key blank receiver opening 132, and pins are inserted intoholes on the key carrier 14 to eject the key blank 15 from the keycarrier 14. Once ejected, the cut key blank 15 falls into the duplicatedkey retrieval opening 26 and the key carrier 14 runs off the end of thetrack of the belt drive feeder 82 into a garbage chute.

In any of the embodiments of automated key duplication systems describedherein, the system may comprise one or more processors 11 associatedwith the key identification system 4, the key cutting system 6, the keyblank storage system 8, 108, the key blank transfer system 10, 110, orany combination thereof. The one or more processors 11 are configured torun software operative to provide the functions needed to initiate thesteps required for key duplication and customer interaction, as well asreporting functions and data transfer between the different systems asneeded.

By way of specific example, a person may use the key identificationsystem 4 to identify a master key. The key identification system 4 sendsidentification data to the processor 11 (e.g. data representing physicalcharacteristics, such as dimensions, patterns, or other parametersindicative of a particular key model either received from the master keyidentifier or from data input by the operator or a combination of both).The processor 11 may access a database defining what key models areknown and determines whether the received identification datacorresponds to a known key model, thus attempting to identify the modelof the master key. If the master key model can be identified, theprocessor 11 accesses a database defining which known key models areavailable at the key blank storage system 8, 108. In particularembodiments with a feedback device, when the processor 11 determinesthat the model of the master key is not available at the key blankdispensing/vending machine associated with the key identification system4 or that the key cutting system 6 associated with the keyidentification system 4 is unable to cut the master key identified, itcommunicates with the feedback device to provide information to the useras to where the user can go to have a duplicate key cut for thatparticular master key.

Also contemplated herein are one or more methods for automatedduplication of a master key. In one or more embodiments, a methodcomprises identifying a master key with a key identification system 4.The master key may be identified with any master key identifierdisclosed herein, incorporated by reference, or otherwise known in theart, such as but not limited to digital cameras, lasers, and the like.Once the mast key has been identified, one or more embodiments comprisedetermining a stock-keeping unit (SKU) associated with the identifiedmaster key identified. The SKU associated with the identified master keymay refer to one or more key blanks that may be cut to duplicate themaster key. One or more methods may further comprise determining, withthe processor 11, a location or coordinates of the SKU in a grid-likekey blank storage system 8, 108 and activating the key blank transferassembly 10, 110 to align with the coordinates of the SKU.

One or more methods for automated duplication of a master key furthercomprise moving a key retrieving apparatus 28, 128 of a key blanktransfer assembly to the SKU of the key blanks 15 and/or key carriers 14stored in the key blank storage system 8, 108 and removably coupling orotherwise retrieving a key blank 15 and/or key carrier 14 with the keyretrieving apparatus 28, 128. Scanning of the SKU of the SKU of theretrieved key blank 15 and/or key carrier may be performed by a scanneroperably coupled to the processor 11 to verify that the retrieved keyblank 15 and/or key carrier 14 comprises the desired SKU. One or moremethods further comprises transferring the one key blank 15 from the keyblank storage system 8, 108 to a key cutting system 6. The method mayfurther comprise inserting the blade of the key blank 15 into a keyblank receiving opening 132 of the key cutting system and cutting thekey blank 15 with the key cutting system 6 to match the identifiedmaster key. Once the key blank has been cut, the method comprisesdispensing the cut key blank to a user through the duplicated keyretrieval opening 26.

In one or more embodiments, a method for automated duplication of amaster key further comprises receiving user instructions or selectionson a user interface 13 associated with the processor 11. Userinstructions or selections may, in various embodiments, pertain to thetype of master key being identified (such as home, automobile, etc.),the desired key blank 15, the style of key blank 15, the number ofduplicated keys desired, and the like.

It will be understood that implementations are not limited to thespecific components disclosed herein, as virtually any componentsconsistent with the intended operation of a method and/or systemimplementation for an automated key duplication system may be utilized.Accordingly, for example, although particular systems may be disclosed,such components may comprise any shape, size, style, type, model,version, class, grade, measurement, concentration, material, weight,quantity, and/or the like consistent with the intended operation of amethod and/or system implementation for an automated key duplicationsystem may be used.

In places where the description above refers to particularimplementations of an automated key duplication system, it should bereadily apparent that a number of modifications may be made withoutdeparting from the spirit thereof and that these implementations may beapplied to other an automated key duplication system. The accompanyingclaims are intended to cover such modifications as would fall within thetrue spirit and scope of the disclosure set forth in this document. Thepresently disclosed implementations are, therefore, to be considered inall respects as illustrative and not restrictive, the scope of thedisclosure being indicated by the appended claims rather than theforegoing description. All changes that come within the meaning of andrange of equivalency of the claims are intended to be embraced therein.

The invention claimed is:
 1. An automated key duplication system,comprising: a system housing; a key identification system housed atleast partially within the system housing and configured to identify amaster key; a key cutting system housed within the system housing; a keyblank storage system housed within the system housing and comprising aplurality of rods, a plurality of key carriers removably coupled to theplurality of rods, and a plurality of key blanks, each one of theplurality of key blanks coupled to a different one of the plurality ofkey carriers; a key blank transfer assembly housed within the systemhousing and comprising a key retrieving apparatus, the key blanktransfer assembly configured to remove one key carrier of the pluralityof key carriers from the key blank storage system with the keyretrieving apparatus and transport the one key carrier and the key blankcoupled thereto from the key blank storage system to the key cuttingsystem; and a duplicated key retrieval opening positioned on the systemhousing to receive the one key blank after the one key blank has beencut.
 2. The automated key duplication system of claim 1, furthercomprising one or more processors in communication with the keyidentification system, the key cutting system, the key blank storagesystem, and the key blank transfer assembly, wherein the one or moreprocessors are configured to receive master key information from the keyidentification system, access a database defining a plurality of knownkey models, compare physical characteristics of the master key withphysical characteristics of key models in the database to identify amodel of the master key, and determine one or more key blanks of theplurality of key blanks that are suitable for cutting to match themaster key.
 3. The automated key duplication system of claim 2, whereinthe key retrieving apparatus is movable along a vertical axis and ahorizontal axis to align with the one key carrier, and movable from thekey blank storage system to a key blank receiving opening of the keycutting system.
 4. The automated key duplication system of claim 3,wherein the plurality of key carriers are positioned by key blank typein at least two rows and at least two columns in the key blank storagesystem.
 5. The automated key duplication system of claim 3, wherein eachof the plurality of key carriers are removably mounted between slots onadjacent rods of the plurality of rods.
 6. The automated key duplicationsystem of claim 5, wherein the key blank transfer assembly furthercomprises a horizontal belt system that moves the key retrievingapparatus along the horizontal axis and a vertical belt system thatmoves the key retrieving apparatus along the vertical axis.
 7. Theautomated key duplication system of claim 6, wherein the key blankstorage system comprises a double-sided storage system comprising twoopposing series of rods of the plurality of rods, and wherein the keyblank transfer assembly is positioned between the two opposing series ofrods of the plurality of rods, the key retrieving apparatus havingaccess to key carriers mounted among each of the two opposing series ofrods.
 8. The automated key duplication system of claim 2, furthercomprising a plurality of linear springs, each linear spring coupled toa different rod of the plurality of rods and configured to bias theplurality of key carriers towards the key blank transfer assembly. 9.The automated key duplication system of claim 8, wherein each keycarrier of the plurality of key carriers comprises one or more aperturesand the key retrieving apparatus comprises one or more tabs positionedto engage with the one or more apertures when the key blank transferassembly moves the one key carrier from the key blank storage system tothe key cutting system.
 10. The automated key duplication system ofclaim 2, further comprising a user interface in electronic communicationwith the one or more processors.
 11. The automated key duplicationsystem of claim 4, wherein the key retrieving apparatus comprises aclamp and the plurality of rods comprises at least four rods, each ofthe at least four rods extending through an aperture on a different oneor more of the plurality of key carriers.